Method and interface for automated loop checking of an industrial process control and automation system

ABSTRACT

A method and interface for automated loop checking of an industrial process control and automation system comprises importing wiring diagrams and alarm setpoints to operating software executing on a hand-held device from a database. The operating software uses the wiring diagrams and alarm setpoints to build an I/O loop check file. The method further includes, installing a dongle adapted to simulate I/O signals on a first terminal block. The dongle making an electrical connection to at least one I/O loop. The method further includes transmitting via a communication link the I/O loop check file to the dongle and instructing the dongle to perform an I/O loop test on the at least one I/O loop by simulating I/O signals based on the I/O loop check file. The results of the I/O loop test is transmitted via the communication link the results to the operating software.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority under 35 U.S.C. § 119(b) to IndiaProvisional Patent Application No. 201911038324, filed on Sep. 23, 2019.This provisional application is hereby incorporated by reference in itsentirety.

TECHNICAL FIELD

This disclosure is generally directed to industrial process control andautomation systems. More specifically, this disclosure is directed to amethod and interface for automating the checking of I/O loops.

BACKGROUND

Loop checking is the process of validating and verifying the accuracy ofcables that are laid from control panels to field instruments, whichensures that the right transmitter is connect to the correctInput/Output (I/O) port of a controller. Loop checking is an importantactivity in a plant during installation, commissioning and maintenancephases. In many plants, loop checking is a mandatory activity thatcannot be eliminated and consumes large amounts of time, cost andmanpower. Loop checking requires multiple people working together toensure that the loop is properly connected to I/O ports and amarshalling cabinet. Loop checking needs to be completed before poweringup of a field instrument or marshalling cabinet.

Process Industries like oil & gas, petrochemicals, refineries etc.involves multiple stages of validation and verification in the projectlifecycle. Validation and verification of input/output (I/O) loop checksneed to be completed before starting the commissioning and startup ofthe plant. During a projects lifecycle, the validation of I/O loop checkactivities occur at PRE-FAT (pre-factory acceptance testing), FAT(factory acceptance test) and SAT (site acceptance test) and validatethe hardwired I/O loop from the junctions boxes, field terminationassemblies and marshalling cabinets to field instruments. This ismanually intensive, repetitive & time-consuming activity is required todemonstrate that the correct wiring and configuration has been made foreach I/O channel.

When the cables are checked for failures, the cables between junctionboxes, field termination assemblies are tested by detecting a signaltransmitted from a control panel to specific field devices. Currently,each cable is manually tested by a group of people from a cable source(such as a marshalling cabinet) to a destination (such as a fieldtransmitter), which is time consuming.

SUMMARY

This disclosure provides a method and interface automated loop checkingof an industrial process control and automation system.

In a first embodiment a method is provided. The method comprisesimporting wiring diagrams and alarm setpoints to operating softwareexecuting on a hand-held device from a database. The operating softwareuses the wiring diagrams and alarm setpoints to build an I/O loop checkfile. The method further includes, installing a dongle adapted tosimulate I/O signals on a first terminal block. The dongle making anelectrical connection to at least one I/O loop. The method furtherincludes transmitting via a communication link the I/O loop check fileto the dongle. The method also includes instructing the dongle by theoperating software to perform an I/O loop test on the at least one I/Oloop by simulating I/O signals based on the I/O loop check file andtransmitting via the communication link the results of the I/O loop testto the operating software.

In a second embodiment an apparatus includes a remotely locatedhand-held device configured to execute an operating software to generatean I/O loop check file from I/O loop data transmitted to the operatingsoftware from an engineering database. A dongle is connected to aterminal block and to at least one I/O loop. The dongle includes atleast one processing device executing an I/O simulation applicationconfigured to communicate using a wireless link with the remotelylocated hand-held device. The dongle receives the I/O loop check filefrom the hand-held device using the wireless link and performs an I/Oloop test on the at least one I/O loop. The dongle processing device isalso configured to monitor and track the I/O loop test comparing theresults of the I/O loop test to an expected result, record the resultsof the I/O loop test and transmit using the wireless link the results ofthe I/O loop test to the hand-held device and the operating software.

In a third embodiment a non-transitory computer readable mediumcontaining instruction that when executed by at least one processingdevice cause the at least one processing device to execute an operatingsoftware on a remotely located hand-held device to generate an I/O loopcheck file from I/O loop data transmitted to the application from anengineering database. The medium also contains instructions that, whenexecuted, establish a wireless link with a dongle connected to aterminal block and to at least one I/O loop. The medium also containsinstructions that, when executed by the at least one processing device,transmits using the wireless link the I/O loop check file to the dongleand instructs the dongle to perform an I/O loop test using the I/O loopcheck file and to receive using the wireless link the results of the I/Oloop test from the dongle upon completion of the I/O loop test.

Other technical features may be readily apparent to one skilled in theart from the following figures, descriptions, and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of this disclosure, reference is nowmade to the following description, taken in conjunction with theaccompanying drawings, in which:

FIG. 1 illustrates an example industrial control and automation systemaccording to this disclosure;

FIG. 2 illustrates an example system for the automated checking of I/Oloops according to this disclosure;

FIG. 3 is an example perspective view of the dongle according to thisdisclosure;

FIG. 4 is an example exploded perspective view of the dongle accordingto this disclosure;

FIG. 5 illustrates an example electronics section of the dongleaccording to this disclosure;

FIG. 6 illustrates an example method used by the operating software tobuild a loop check file according to this disclosure;

FIG. 7 illustrates an example method for the automated checking of I/Oloops according to this disclosure;

FIG. 8 is an example of a set-up display of the graphic user interfaceof the operating software for the automated checking of I/O loopsaccording to this disclosure;

FIG. 9 is an example of a display of output from the graphic userinterface of the operating software representing the association ofdongles with terminal blocks for the automated checking of I/O loopsaccording to this disclosure;

FIG. 10 is an example of a display of output from the graphic userinterface of the operating software representing the status of I/O loopchecks for according to this disclosure; and

FIG. 11 is an example of a display of output from the graphic userinterface of the operating software representing reports and informationof the I/O loops checked according to this disclosure.

DETAILED DESCRIPTION

The figures, discussed below, and the various embodiments used todescribe the principles of the present invention in this patent documentare by way of illustration only and should not be construed in any wayto limit the scope of the invention. Those skilled in the art willunderstand that the principles of the invention may be implemented inany type of suitably arranged device or system.

FIG. 1 illustrates an example industrial process control and automationsystem 100 according to this disclosure. As shown in FIG. 1, the system100 includes various components that facilitate production or processingof at least one product or other material. For instance, the system 100is used here to facilitate control over components in one or multipleplants 101 a-101 n. Each plant 101 a-101 n represents one or moreprocessing facilities (or one or more portions thereof), such as one ormore manufacturing facilities for producing at least one product orother material. In general, each plant 101 a-101 n may implement one ormore processes and can individually or collectively be referred to as aprocess system. A process system generally represents any system orportion thereof configured to process one or more products or othermaterials in some manner.

In FIG. 1, the system 100 is implemented using the Purdue model ofprocess control. In the Purdue model, “Level 0” may include one or moresensors 102 a and one or more actuators 102 b. The sensors 102 a andactuators 102 b represent components in a process system that mayperform any of a wide variety of functions. For example, the sensors 102a could measure a wide variety of characteristics in the process system,such as temperature, pressure, flow rate, or a voltage transmittedthrough a cable. Also, the actuators 102 b could alter a wide variety ofcharacteristics in the process system. The sensors 102 a and actuators102 b could represent any other or additional components in any suitableprocess system. Each of the sensors 102 a includes any suitablestructure for measuring one or more characteristics in a process system.Each of the actuators 102 b includes any suitable structure foroperating on or affecting one or more conditions in a process system.

At least one network 104 is coupled to the sensors 102 a and actuators102 b. The network 104 facilitates interaction with the sensors 102 aand actuators 102 b. For example, the network 104 could transportmeasurement data from the sensors 102 a and provide control signals tothe actuators 102 b. The network 104 could represent any suitablenetwork or combination of networks. As particular examples, the network104 could represent an Ethernet network, an electrical signal network(such as a HART or FOUNDATION FIELDBUS (FF) network), a pneumaticcontrol signal network, or any other or additional type(s) ofnetwork(s).

In the Purdue model, “Level 1” may include one or more controllers 106,which are coupled to the network 104. Among other things, eachcontroller 106 may use the measurements from one or more sensors 102 ato control the operation of one or more actuators 102 b. For example, acontroller 106 could receive measurement data from one or more sensors102 a and use the measurement data to generate control signals for oneor more actuators 102 b. Multiple controllers 106 could also operate inredundant configurations, such as when one controller 106 operates as aprimary controller while another controller 106 operates as a backupcontroller (which synchronizes with the primary controller and can takeover for the primary controller in the event of a fault with the primarycontroller). Each controller 106 includes any suitable structure forinteracting with one or more sensors 102 a and controlling one or moreactuators 102 b. Each controller 106 could, for example, represent amultivariable controller, such as a Robust Multivariable PredictiveControl Technology (RMPCT) controller or other type of controllerimplementing model predictive control (MPC) or other advanced predictivecontrol (APC). As a particular example, each controller 106 couldrepresent a computing device running a real-time operating system.

Two networks 108 are coupled to the controllers 106. The networks 108facilitate interaction with the controllers 106, such as by transportingdata to and from the controllers 106. The networks 108 could representany suitable networks or combination of networks. As particularexamples, the networks 108 could represent a pair of Ethernet networksor a redundant pair of Ethernet networks, such as a FAULT TOLERANTETHERNET (FTE) network from HONEYWELL INTERNATIONAL INC.

At least one switch/firewall 110 couples the networks 108 to twonetworks 112. The switch/firewall 110 may transport traffic from onenetwork to another. The switch/firewall 110 may also block traffic onone network from reaching another network. The switch/firewall 110includes any suitable structure for providing communication betweennetworks, such as a HONEYWELL CONTROL FIREWALL (CF9) device. Thenetworks 112 could represent any suitable networks, such as a pair ofEthernet networks or an FTE network.

In the Purdue model, “Level 2” may include one or more machine-levelcontrollers 114 coupled to the networks 112. The machine-levelcontrollers 114 perform various functions to support the operation andcontrol of the controllers 106, sensors 102 a, and actuators 102 b,which could be associated with a particular piece of industrialequipment (such as a boiler or other machine). For example, themachine-level controllers 114 could log information collected orgenerated by the controllers 106, such as measurement data from thesensors 102 a or control signals for the actuators 102 b. Themachine-level controllers 114 could also execute applications thatcontrol the operation of the controllers 106, thereby controlling theoperation of the actuators 102 b. In addition, the machine-levelcontrollers 114 could provide secure access to the controllers 106. Eachof the machine-level controllers 114 includes any suitable structure forproviding access to, control of, or operations related to a machine orother individual piece of equipment. Each of the machine-levelcontrollers 114 could, for example, represent a server computing devicerunning a MICROSOFT WINDOWS operating system. Although not shown,different machine-level controllers 114 could be used to controldifferent pieces of equipment in a process system (where each piece ofequipment is associated with one or more controllers 106, sensors 102 a,and actuators 102 b).

One or more operator stations 116 are coupled to the networks 112. Theoperator stations 116 represent computing or communication devicesproviding user access to the machine-level controllers 114, which couldthen provide user access to the controllers 106 (and possibly thesensors 102 a and actuators 102 b). As particular examples, the operatorstations 116 could allow users to review the operational history of thesensors 102 a and actuators 102 b using information collected by thecontrollers 106 and/or the machine-level controllers 114. The operatorstations 116 could also allow the users to adjust the operation of thesensors 102 a, actuators 102 b, controllers 106, or machine-levelcontrollers 114. In addition, the operator stations 116 could receiveand display warnings, alerts, or other messages or displays generated bythe controllers 106 or the machine-level controllers 114. Each of theoperator stations 116 includes any suitable structure for supportinguser access and control of one or more components in the system 100.Each of the operator stations 116 could, for example, represent acomputing device running a MICROSOFT WINDOWS operating system.

At least one router/firewall 118 couples the networks 112 to twonetworks 120. The router/firewall 118 includes any suitable structurefor providing communication between networks, such as a secure router orcombination router/firewall. The networks 120 could represent anysuitable networks, such as a pair of Ethernet networks or an FTEnetwork.

In the Purdue model, “Level 3” may include one or more unit-levelcontrollers 122 coupled to the networks 120. Each unit-level controller122 is typically associated with a unit in a process system, whichrepresents a collection of different machines operating together toimplement at least part of a process. The unit-level controllers 122perform various functions to support the operation and control ofcomponents in the lower levels. For example, the unit-level controllers122 could log information collected or generated by the components inthe lower levels, execute applications that control the components inthe lower levels, and provide secure access to the components in thelower levels. Each of the unit-level controllers 122 includes anysuitable structure for providing access to, control of, or operationsrelated to one or more machines or other pieces of equipment in aprocess unit. Each of the unit-level controllers 122 could, for example,represent a server computing device running a MICROSOFT WINDOWSoperating system. Although not shown, different unit-level controllers122 could be used to control different units in a process system (whereeach unit is associated with one or more machine-level controllers 114,controllers 106, sensors 102 a, and actuators 102 b).

Access to the unit-level controllers 122 may be provided by one or moreoperator stations 124. Each of the operator stations 124 includes anysuitable structure for supporting user access and control of one or morecomponents in the system 100. Each of the operator stations 124 could,for example, represent a computing device running a MICROSOFT WINDOWSoperating system.

At least one router/firewall 126 couples the networks 120 to twonetworks 128. The router/firewall 126 includes any suitable structurefor providing communication between networks, such as a secure router orcombination router/firewall. The networks 128 could represent anysuitable networks, such as a pair of Ethernet networks or an FTEnetwork.

In the Purdue model, “Level 4” may include one or more plant-levelcontrollers 130 coupled to the networks 128. Each plant-level controller130 is typically associated with one of the plants 101 a-101 n, whichmay include one or more process units that implement the same, similar,or different processes. The plant-level controllers 130 perform variousfunctions to support the operation and control of components in thelower levels. As particular examples, the plant-level controller 130could execute one or more manufacturing execution system (MES)applications, scheduling applications, or other or additional plant orprocess control applications. Each of the plant-level controllers 130includes any suitable structure for providing access to, control of, oroperations related to one or more process units in a process plant. Eachof the plant-level controllers 130 could, for example, represent aserver computing device running a MICROSOFT WINDOWS operating system.

Access to the plant-level controllers 130 may be provided by one or moreoperator stations 132. Each of the operator stations 132 includes anysuitable structure for supporting user access and control of one or morecomponents in the system 100. Each of the operator stations 132 could,for example, represent a computing device running a MICROSOFT WINDOWSoperating system.

At least one router/firewall 134 couples the networks 128 to one or morenetworks 136. The router/firewall 134 includes any suitable structurefor providing communication between networks, such as a secure router orcombination router/firewall. The network 136 could represent anysuitable network, such as an enterprise-wide Ethernet or other networkor all or a portion of a larger network (such as the Internet).

In the Purdue model, “Level 5” may include one or more enterprise-levelcontrollers 138 coupled to the network 136. Each enterprise-levelcontroller 138 is typically able to perform planning operations formultiple plants 101 a-101 n and to control various aspects of the plants101 a-101 n. The enterprise-level controllers 138 can also performvarious functions to support the operation and control of components inthe plants 101 a-101 n. As particular examples, the enterprise-levelcontroller 138 could execute one or more order processing applications,enterprise resource planning (ERP) applications, advanced planning andscheduling (APS) applications, or any other or additional enterprisecontrol applications. Each of the enterprise-level controllers 138includes any suitable structure for providing access to, control of, oroperations related to the control of one or more plants. Each of theenterprise-level controllers 138 could, for example, represent a servercomputing device running a MICROSOFT WINDOWS operating system. In thisdocument, the term “enterprise” refers to an organization having one ormore plants or other processing facilities to be managed. Note that if asingle plant 101 a is to be managed, the functionality of theenterprise-level controller 138 could be incorporated into theplant-level controller 130.

Access to the enterprise-level controllers 138 may be provided by one ormore operator stations 140. Each of the operator stations 140 includesany suitable structure for supporting user access and control of one ormore components in the system 100. Each of the operator stations 140could, for example, represent a computing device running a MICROSOFTWINDOWS operating system.

Various levels of the Purdue model can include other components, such asone or more databases. The database(s) associated with each level couldstore any suitable information associated with that level or one or moreother levels of the system 100. For example, a historian 141 can becoupled to the network 136. The historian 141 could represent acomponent that stores various information about the system 100. Thehistorian 141 could, for instance, store information used duringproduction scheduling and optimization. The historian 141 represents anysuitable structure for storing and facilitating retrieval ofinformation. Although shown as a single centralized component coupled tothe network 136, the historian 141 could be located elsewhere in thesystem 100, or multiple historians could be distributed in differentlocations in the system 100.

In particular embodiments, the various controllers and operator stationsin FIG. 1 may represent computing devices. For example, each of thecontrollers could include one or more processing devices 142 and one ormore memories 144 for storing instructions and data used, generated, orcollected by the processing device(s) 142. Each of the controllers couldalso include at least one network interface 146, such as one or moreEthernet interfaces or wireless transceivers. Also, each of the operatorstations could include one or more processing devices 148 and one ormore memories 150 for storing instructions and data used, generated, orcollected by the processing device(s) 148. Each of the operator stationscould also include at least one network interface 152, such as one ormore Ethernet interfaces or wireless transceivers.

In accordance with this disclosure, various components of the system 100support a process for an automated loop check in the system 100. Forexample, the controllers 104 a-104 b may represent field devicecontrollers, and the process elements 102 a-102 b may represent fielddevices. Additional details regarding this functionality are providedbelow.

Although FIG. 1 illustrates one example of an industrial process controland automation system 100, various changes may be made to FIG. 1. Forexample, a control system could include any number of sensors,actuators, controllers, servers, operator stations, and networks. Also,the makeup and arrangement of the system 100 in FIG. 1 is forillustration only. Components could be added, omitted, combined, orplaced in any other suitable configuration according to particularneeds. Further, particular functions have been described as beingperformed by particular components of the system 100. This is forillustration only. In general, process control systems are highlyconfigurable and can be configured in any suitable manner according toparticular needs.

FIG. 2 illustrates an example the marshalling cabinet 200 according tothis disclosure. For ease of explanation, the marshalling cabinet 200 isdescribed as being used in the system 100 of FIG. 1. For example, themarshalling cabinet 200 may be located between a system cabinet 205housing controllers 106, and process elements 102 a and 102 b, and otherhardware such as switch/firewall 110, or a combination of the componentsdescribed in FIG. 1. However, the marshalling cabinet 200 could also beused in any other suitable system.

The marshalling cabinet 200 includes field termination block 212 andfield termination relay hardware 215. Only one field termination block212 is shown in FIG. 2 for ease of illustration, however, it is wellknown to those skilled in this art, that marshalling cabinets maycontaining a plurality of terminal blocks 212 housed in cabinet 200. Thefield termination block 212 connects wire cables between cabinet 200 andprocess elements, such as actuators, sensors and other processinstruments installed in the automation system. The system cabinet 205connects to the marshaling cabinet 200 via the field termination relayhardware 215 and wiring cables 220 a and 220 b. The marshalling cabinet200, further connects to a plurality of junction boxes 210, and to aplurality of process instruments 230 a-230 d.

The marshalling cabinet 200 receives signals transmitted from one of theprocess instruments 230 a-230 d through a junction boxes 210 and cablebundles 225. Each process instrument 230 a-230 d is coupled to arespective junction box 210 via a cable 231. The cables 231 are bundledat the junction boxes 210 to form a cable bundle 225 upstream of thejunction box 210. A junction box 211 can also be used to combinemultiple cable bundles 225 into a single cable bundle 228, asillustrated between the junction box 211 and the marshalling cabinet200.

Although FIG. 2 illustrates one example of a junction box 210, 211,various changes may be made to FIG. 2. For example, the number(s) andtype(s) of components shown in FIG. 2 and the functional divisions ofthe junction boxes 210, 211, marshaling cabinet 200, system cabinet 205and their included hardware shown in FIG. 2 are for illustration onlyVarious components in FIG. 2 could be omitted, combined, or furthersubdivided and additional components could be added according toparticular needs.

The automated loop check system of the disclosure employees anintelligent dongle 250 arranged to connect to the terminal blocks ofcabinet 200 such as terminal block 212 and simulate signals based oninput/output information provided to the dongle 250 from operatingsoftware 240 operating in a remotely located mobile hand-held device260. The dongle 250 can also be installed to terminal blocks in thejunction boxes 210 in the same manner as will be explained for theterminal block 212 of the marshalling cabinet 200.

Operating software 240 is installed on a hand-held mobile device 260,that can operate at a remote location, for example, such as a cellulartelephone, data pad, tablet, or hand-held computer operating any on anIOS an ANDROID or WINDOWS operating system. The operating software 240controls the sequencing of execution of tests through dongle 250 basedon personality information of each process instrument connected to theterminal block 212. The operating software 240 automatically generatesan I/O loop check file using predefined library functions based onproject engineering database input. The I/O loop check file isdownloaded to dongle 250 for execution and testing of the I/O loopsconnected to the dongle 250.

The hand-held device 260 is connected via a wireless WI-FI or BLUETOOTHlow energy (BLE) communication link connection to the dongle 250.Additionally, the hand-held device 250 is further connected via awireless WI-FI connection to an engineering workstation 270, as well asto the cloud 290 through WAP 285 mounted on L2 switch 286 as shown inFIG. 2. The cloud connections are through integrity policy enforcement(IPE) security that hosts a smart plant instrumentation (SPI) databasethat among other functions within an industrial process control andautomation system design, defines the overall wiring connections betweenthe sensors, actuators, controllers, servers, operator stations, andnetworks of the industrial process control and automation system.

Turning know to FIG. 3, the dongle 350 of the disclosure is illustrated.Dongle 350 is comprised of an electronics section 355 and a separateterminal section 360. The terminal section 360 provides a snap-inarrangement of terminal pins 365. For example, in the terminal section360 shown in FIG. 3, an 8-channel snap-in terminal section 360 has 16terminal pins 365. Each terminal pin is adapted to engage with andestablish an electrical connection to terminal sockets found in theterminal block 212. Various snap-in terminal pins 365 (not shown) can beinstalled in the terminal section 360 adapted to plug into specificelectrical sockets of the terminal block 212. The terminal section 360also includes an electrical connector (not shown) that engages a similarconnector on the electronics section 355 that passes electrical signalsbetween the terminal pins 365 and the electronic section 355 of thedongle 350.

As can be best seen at FIG. 4, the dongle 350 also includes aclip/holder mechanism 460 that is used to retain the dongle 350 securelyto the terminal block 212. The clip/holder 460 is mounted to the dongle350 in a manner that allows the clip arm 461 of holder mechanism 460 tobe moved latterly away from the terminal block. Applying pressure to arm461 moves members 462 and hooks 463 laterally away from the terminalblock 212. The dongle is installed by inserting pins 365 intocomplementary electrical sockets in terminal block 212. Attaching hooks463′ to engage edge 213 of terminal block 212. Releasing the clip arm461 allows hooks 463 to grab edge 214 of terminal block 212 and retainthe dongle 350 on the terminal block 212 as is shown in FIG. 4. Lateralmovement of the clip/holder can be accomplished, for example, with theuse of a spring (not shown) which will allow the lateral movement of theclip arm 461 by physical manipulation or by use of a live hinge that ismade from a thinner cross-section of the material making-up the housingof the dongle 350.

The electronics section 355 of dongle 350 is shown schematically at FIG.5. The electronics section 500 includes at least one processor 502, atleast one storage device 504, at least one communications unit 506, andat least one input/output (I/O) unit 508. Processor 502 can executeinstructions, such as those that may be loaded into memory 504.Processor 502 denotes any suitable processing device, such as one ormore microprocessors, microcontrollers, digital signal processors,application specific integrated circuits (ASICs), field programmablegate arrays (FPGAs), or discrete circuitry.

The memory 510 and a persistent storage 512 are examples of storagedevices, which represent any structure(s) capable of storing andfacilitating retrieval of information (such as data, program code,and/or other suitable information on a temporary or permanent basis).The memory 510 may represent a RAM or any other suitable volatile ornon-volatile storage device(s). The persistent storage 512 may containone or more components or devices supporting longer-term storage ofdata, such as a ROM, and flash memory, or the like. Memory 510 can beused to store for example, the intermediate results of the operation ofthe processor 502 and the test files to be executed by dongle 350 aswell as the results of the executed loop tests. The persistent storagemay be used, for example, for storing the processor operating system,and the software for performing self-testing and calibration of thedongle 350.

The communications unit 506 supports communications with other systemsor devices. For example, the communications unit 506 could include atleast one network interface facilitating communications over a wirelesscommunication protocol such as WI-FI or BLE.

The I/O unit 508 allows for the input and output of data and iselectrically connected through a connector (not shown) to the terminalsection 360 of dongle 350. For example, the I/O unit 508 may provide aconnection through the terminal section 360 for providing simulated I/Ocommands to a process instrument. The I/O unit 508 supports 8 channelsof any IO Type with functional 5-point analog test support. The I/O unit508 drives signals to the I/O loops under test via the 8-channelterminal section 360 through the terminal block 212. The I/O unit 508supports I/O configurations downloaded from the I/O loop operatingsoftware 240 such as analog input (AI), digital input (DI), digitaloutput (DO), Analog Output (AO), Thermocouple/RTD, Low LevelMultiplexing/Low Level analog input End of Line (LLMux/LLAI EOL)monitoring (Short/Open) and burnout detection.

The execution of I/O loop tests by dongle 250 is based on thepersonality information of each I/O loop or I/O loop channel. Thepersonality information is compiled from engineering data from theautomation and control system and on inputs received from a smart plantinstrumentation database (SPI). As shown on FIG. 6, a loop check file630 is created automatically by the operating software 240 by importingto the operating software 240 wiring diagrams 610 of the wiring andcabling path between the marshalling cabinet 200, or junction box 210and the process instruments 230 a-230 d to be tested. The wiring diagram610 is provided and downloaded to the operating software 240 from amaster wiring database from the project engineering workstation 270 orfrom an SPI located in the cloud 290. Alarm trip set points 615 are alsoinput from the project engineering workstation 270 for the processinstruments 230 a-230 d connected to the I/O loop channel under test.Next the type of test to be run is selected from a predefined library620, for example, an analog input test or a digital input test. Thewiring data 610 and alarm trip setpoints 615 and test types 620 buildthe I/O loop check file 630 which is downloaded to the dongle 350 viathe WI-FI or BLE communication link. The I/O loop check file 630 is thetest image for the personality information of a specific I/O loopchannel to be tested. The operating software 240 executing on the mobiledevice 260 enables and supervises the execution status of the dongles250.

FIG. 7 illustrates an example method 700 for automatic loop checkingaccording to this disclosure. For ease of understanding, the method 700is described with respect to the marshaling cabinet 200 in FIG. 2.However, the method 700 could be used by any suitable marshalingcabinet, field termination assembly or junction box and in any suitablesystem.

The method 700 includes block 705 in which the I/O channel personalityimage is downloaded to the operating software 240 from the engineeringdatabase and an I/O loop check file 630 is created. In block 710, theoperating software 240 sends a notification to the display of the mobiledevice 260 instructing the field operator to connect the dongle 250 tothe terminal block 212 of the marshaling panel 200. Once the dongle 250is installed, the dongle 250 goes through a series of self-tests andattempts to establish a wireless WI-FI or BLE communication link withthe mobile device 260. As is shown in block 715, if the dongle 250 failsto connect, the dongle attempts the connection again and repeats aconnection attempt until a connection is established between the dongle250 and the mobile device 260.

In block 720, upon establishing a wireless connection between the dongle250 and the mobile device 260, the I/O loop check file 630 is downloadedfrom the operating software 240 to the dongle 250 and the dongleinstructed to simulate the loop check to be performed. For example, ifan analog input loop check is to be performed, the I/O unit 508 of theelectronics section 355 sets up I/O circuitry to perform an analog loopcheck.

Next in block 725, the I/O loop test is performed for the I/O loop orI/O loop channel under test. In block 730, the dongle 250 tracks thetest data which is compared to an expected result for the I/O loop test.If the results of the loop test pass, in block 735 the dongle sends thetest results to the operating software where the results are recorded.The operating software 240 then determines, in block 740, if more I/Oloops checks are to be performed for the terminal block that the dongle250 is installed on, for example, a second I/O loop or I/O channel. TheI/O channel number is incremented in block 745 and a second I/O loopcheck file 630 is downloaded to the dongle 250 for execution.

However, if an I/O loop fails its loop test, the dongle 250, in block736 sends the failed results to the operating software 240 where thefailure is recorded and a determination is made in block 740 if moreloops checks are to be performed for the terminal block that the dongleis installed on. If one or more I/O loop tests are required to be made,the I/O channel number is incremented in block 745 and a second I/O loopcheck file is downloaded to the dongle 250 for execution.

In block 750, once all I/O loop tests are complete for all I/O loopchannels connected to the dongle 250, a notification is displayed on themobile device 260, for the field operator to install the dongle 250 tothe next terminal block 212 of the marshalling panel 200. The dongle 250in this embodiment is able to connect to eight I/O loops or I/O loopchannels and perform eight I/O loop tests before requiring it to bemoved to the next set of I/O loops to be tested.

Although FIG. 7 illustrates one example of a method for automatic loopchecking, various changes may be made to FIG. 7. For example, whileshown as a series of steps, various steps shown in FIG. 7 could overlap,occur in parallel, or occur multiple times. Moreover, some steps couldbe combined or removed, and additional steps could be added.

FIG. 8 shows a display 800 presented to the user on mobile device 260 bya user interface of operating software 240 to the field operator whensetting up a dongle 250. The display 800 includes information 805identifying the industrial process control and automation system, thename of the marshalling cabinet 810 and a pane including thumbnailimages 820 of the terminal blocks installed in the cabinet. Eachterminal block thumbnail 820 can have a unique name associated with it,which would be shown as label 825 over the specific terminal blocksthumbnail 820. On the left side of the screen a dongle tray is displayedwith a series of thumbnail images representing dongles, such as donglethumbnail 830. Each dongle thumbnail 830 would be associated with aparticular I/O loop check file 630 that has been completed by theoperating software 240. Each dongle thumbnail 830 therefore wouldrepresent a personality image of the I/O loop check file 630 built to beexecuted for a specific terminal block 820. Each dongle is furtheridentified by a specific ID. For example, the ID could be a specificnumeral representing the dongle or a unique alphanumeric name.

In order to run an automated I/O loop check the appropriate donglethumbnail 830 from the dongle tray is dragged and dropped on a specificterminal block thumbnail 820 to be tested as shown by arrow 840. Thedongle thumbnail 830 can be dragged and dropped on a selected terminalblock using for example, the field operator's finger, a stylus, trackpad or by other means for completing the selection such as using moderninput/output mechanisms such as drop-down menus and mouse right-clicks.Testing is started when the “begin testing” button 835 is pressed. TheI/O loop check file 630 is then downloaded to the dongle 250 associatedwith the terminal block selected and the I/O loop testing started.

As can be seen in FIG. 9, once a dongle thumbnail 830 is associated witha terminal thumbnail 820 the terminal block changes from a dashed linesquare to a solid square 920 signifying that a dongle and a loop checkfile has been associated with the terminal block. I/O loop checkscompleted successfully, are indicated by a solid image color as shown.However, upon a failure of a I/O loop check, the terminal blockthumbnail 940 indicates a failed state by displaying a failure color andthe dongle image ID associated with the loop failure is marked andidentified 950 for later troubleshooting by the field operator.

FIG. 10 illustrates a display 1000 presented to the user on the mobiledevice 260 by the graphic user interface of operating software 240 whenthe dongle 250 is physical installed on terminal block 212 and executingthe I/O loop checks. The dongle ID 1005 is indicated on the screendisplay header. As is shown in FIG. 10, a pictorial representation ofthe terminal block 212 is displayed showing, in this example, eight I/Oloop channels being tested. Each I/O loop channel signifying an I/O loopbeing tested by an I/O loop check file 630. Overall progress of thetests being run by the dongle 250 is shown in the screen header bydisplay 1010 as well as the elapsed time of the test at 1015. Theterminal block under test is also identified by a label 1020 thatidentifies the terminal block being tested. Each channel includesindication if an I/O loop check has passed the testing 1025, is inprogress 1030, or failed (not shown). The tests can be stopped and orresumed using the function buttons 1035, 1040 respectively on the bottomof the screen.

Turning now to FIG. 11, a display 1100 presented to the user on themobile device 260 by the graphic user interface of operating software240 reporting the test results of the I/O loop checks. The display 1100includes information 1105 identifying the industrial process control andautomation system, the name of the marshalling cabinet 1110 and thetotal cabinets tested 1112. The report also includes summary of testprogress. The information is presented graphically as a horizontal linesignifying a percentage of completion as well as numerically providing apercentage of completion. For example, a rate of completion of I/O loopchecks is shown by line 1115 and a percentage of completion shown bypercentage number 1116. Additionally, the same method is used to showhow many I/O loop checks have passed 1120, 2021, as well as, how manyloop checks have failed 1130, 1131. The report display can be accessedat any time during the testing of the I/O loops to indicate the statusof the testing.

A report pane 1150 lists reports for I/O loop checks run a specificdongle 250 identified by the dongle ID 1155. The report lists in acolumnar fashion the terminal header 1160, the I/O type of loop checkperformed 1165, for example an analog output (AO) check or digital input(DI) check, a system tag 1170, the channel number 1175 and the result ofeach I/O loop check 1180. Information as to the values returned in theI/O loop check is also presented for the field operator use at column1185. If more than one dongle was used in the test, the display screencan be scrolled either upward or downward to view the other test resultsfor all the dongle IDs associated with the cabinet.

The test reports for each of the I/O loop test is also recorded by theoperating software 240 and uploaded to the project engineering diabaseat an engineering workstation 270 or to the cloud 290. The test resultsare validated automatically and can be retrieved at any time. Once adongle 250 is associated with a terminal block 212 and a I/O loop checkstarted, the system performs the I/O loop checks automatically withoutthe need of a test engineer or field operator to watch over the testing.Further, I/O loop checks can be performed overnight and can be performon multiple systems at the same time.

In some embodiments, various functions described in this patent documentare implemented or supported by a computer program that is formed fromcomputer readable program code and that is embodied in a computerreadable medium. The phrase “computer readable program code” includesany type of computer code, including source code, object code, andexecutable code. The phrase “computer readable medium” includes any typeof medium capable of being accessed by a computer, such as read onlymemory (ROM), random access memory (RAM), a hard disk drive, a compactdisc (CD), a digital video disc (DVD), or any other type of memory. A“non-transitory” computer readable medium excludes wired, wireless,optical, or other communication links that transport transitoryelectrical or other signals A non-transitory computer readable mediumincludes media where data can be permanently stored and media where datacan be stored and later overwritten, such as a rewritable optical discor an erasable memory device.

The description in this patent document should not be read as implyingthat any particular element, step, or function is an essential orcritical element that must be included in the claim scope. Also, none ofthe claims is intended to invoke 35 U.S.C. § 112(f) with respect to anyof the appended claims or claim elements unless the exact words “meansfor” or “step for” are explicitly used in the particular claim, followedby a participle phrase identifying a function Use of terms such as (butnot limited to) “mechanism,” “module,” “device,” “unit,” “component,”“element,” “member,” “apparatus,” “machine,” “system,” “processor,”“processing device,” or “controller” within a claim is understood andintended to refer to structures known to those skilled in the relevantart, as further modified or enhanced by the features of the claimsthemselves, and is not intended to invoke 35 U.S.C. § 112(f).

It may be advantageous to set forth definitions of certain words andphrases used throughout this patent document. The terms “application”and “program” refer to one or more computer programs, softwarecomponents, sets of instructions, procedures, functions, objects,classes, instances, related data, or a portion thereof adapted forimplementation in a suitable computer code (including source code,object code, or executable code) The terms “include” and “comprise,” aswell as derivatives thereof, mean inclusion without limitation. The term“or” is inclusive, meaning and/or. The phrase “associated with,” as wellas derivatives thereof, may mean to include, be included within,interconnect with, contain, be contained within, connect to or with,couple to or with, be communicable with, cooperate with, interleave,juxtapose, be proximate to, be bound to or with, have, have a propertyof, have a relationship to or with, or the like. The phrase “at leastone of,” when used with a list of items, means that differentcombinations of one or more of the listed items may be used, and onlyone item in the list may be needed. For example, “at least one of: A, B,and C” includes any of the following combinations: A, B, C, A and B, Aand C, B and C, and A and B and C.

While this disclosure has described certain embodiments and generallyassociated methods, alterations and permutations of these embodimentsand methods will be apparent to those skilled in the art. Accordingly,the above description of example embodiments does not define orconstrain this disclosure. Other changes, substitutions, and alterationsare also possible without departing from the spirit and scope of thisdisclosure, as defined by the following claims.

What is claimed is:
 1. A method comprising: importing wiring diagramsand alarm setpoints to operating software executing on a hand-helddevice from a database, the operating software using the wiring diagramsand alarm setpoints to build an I/O loop check file; installing a dongleadapted to simulate I/O signals on a first terminal block, the donglemaking an electrical connection to at least one I/O loop; transmittingvia a communication link the I/O loop check file to the dongle;instructing the dongle by the operating software to perform an I/O looptest on the at least one I/O loop by simulating I/O signals based on theI/O loop check file; and transmitting via the communication link theresults of the I/O loop test to the operating software.
 2. The method ofclaim 1, wherein: the operating software includes a library ofpredefined test types; and incorporating a test type with the wiringdiagrams and alarm setpoints to build the I/O loop test file.
 3. Themethod of claim 2, wherein the database of wiring diagrams and alarmsetpoints, are stored in an engineering workstation; and transmittingvia the communication link the wiring diagrams and alarm setpoints tothe hand-held device from engineering workstation.
 4. The method ofclaim 2, wherein the database of wiring diagrams and alarm setpoints,are stored in a database located in the cloud; and transmitting via thecommunication link the wiring diagrams and alarm setpoints to thehand-held device from the cloud.
 5. The method of claim 1, whereintransmitting uses a WI-FI communication link.
 6. The method of claim 1,wherein transmitting uses a BLUETOOTH low energy (BLE) communicationlink.
 7. The method of claim 2, wherein the dongle; monitors and tracksthe I/O loop test comparing the results of the I/O loop test to anexpected result.
 8. The method of claim 2, wherein the method furtherincludes: recording the results of the I/O loop test by the dongle; 9.The method of claim 2 wherein the first terminal block includes aplurality of terminal sockets connected to a plurality of I/O loops, themethod further comprising: building an I/O loop check file for a firstI/O loop of the plurality of I/O loops; installing the dongle to thefirst terminal block, the dongle making an electrical connection to eachof the plurality of I/O loops; downloading an I/O loop check file forthe first I/O loop to the dongle; instructing the dongle to simulate I/Osignals and perform an I/O loop test on the first I/O loop; monitoringand tracking the first I/O loop test comparing the results of the I/Oloop test to an expected result; recording the results of the first I/Oloop test by the dongle; and uploading the results of the first I/O looptest to the operating software.
 10. The method of claim 9, wherein themethod further includes: determining by the operating software if all ofthe plurality of the I/O loops have been tested; incrementing a channelnumber corresponding to a another I/O loop; downloading an I/O loopcheck file for another I/O loop to the dongle; and instructing thedongle to simulate I/O signals and perform an I/O loop test on the otherI/O loop.
 11. The method of claim 10, wherein: when all I/O loops havebeen tested; sending a notification to a field operator to install thedongle to a second terminal block.
 12. An apparatus comprising: aremotely located hand-held device configured to execute operatingsoftware to generate an I/O loop check file from I/O loop datatransmitted to the operating software from an engineering database; adongle connected to a terminal block and to at least one I/O loop, thedongle including at least one processing device executing an I/Osimulation application configured when executing the I/O simulationapplication to: communicate using a wireless link with the remotelylocated hand-held device; receive the I/O loop check file from thehand-held device using the wireless link; perform an I/O loop test onthe at least one I/O loop; monitor and track the I/O loop test comparingthe results of the I/O loop test to an expected result; record theresults of the I/O loop test; and transmit using the wireless link theresults of the I/O loop test to the hand-held device and the operatingsoftware.
 13. The apparatus of claim 12, wherein the operating softwareincludes a user interface display that is operated by a user on thehand-held device to: select a thumbnail image of a dongle representing agenerated I/O loop check file; associate a thumbnail image of a dongleto a terminal block connected to at least one I/O loop by dragging anddropping the thumbnail image of the dongle on the terminal block; andthe user selecting an input to begin testing, wherein the I/O check fileis transmitted using the wireless link from the operating software tothe dongle connected on the terminal block to perform the I/O loop teston the at least one I/O loop.
 14. The apparatus of claim 13, wherein theoperating software includes a user interface display that is operated bya user on the hand-held device to: present an image to the user of theprogress and result of the I/O loop test on the least one I/O loop; theimage of the results presented to the user based on the results of theI/O test transmitted to the operating software by the dongle.
 15. Theapparatus of claim 12, wherein: the operating software includes alibrary of predefined test types and the I/O loop data includes wiringdiagrams and alarm setpoints; the operating software is executed tobuild the I/O loop test file from the library of test types using thewiring diagrams and alarm setpoints; and the operating softwaredisplaying the I/O loop test as a thumbnail image of a dongle on theuser interface display on the hand-held device.
 16. The apparatus ofclaim 15, wherein the wiring diagrams and alarm setpoints, are stored inan engineering workstation database and the engineering workstationincludes a wireless link; and the wiring diagrams and alarm setpointsare transmitted using the wireless link to the hand-held device fromengineering workstation.
 17. The apparatus of claim 15, wherein thewiring diagrams and alarm setpoints, are stored in a database located inthe cloud, the cloud connected to the wireless link; and The wiringdiagrams and alarm setpoints are transmitted using the wireless link tothe hand-held device from the cloud.
 18. The apparatus of claim 12,wherein the wireless link uses WI-FI communication signals.
 19. Themethod of claim 1, wherein the wireless link uses BLUETOOTH low energy(BLE) communication signals.
 20. A non-transitory computer readablemedium containing instruction that when executed by at least oneprocessing device cause the at least one processing device to: executean operating software on a remotely located hand-held device to generatean I/O loop check file from I/O loop data transmitted to the applicationfrom an engineering database; establish a wireless link with a dongleconnected to a terminal block and to at least one I/O loop; transmitusing the wireless link the I/O loop check file to the dongle andinstruct the dongle to perform an I/O loop test using the I/O loop checkfile; and receive using the wireless link the results of the I/O looptest from the dongle upon completion of the I/O loop test.